Beer
Even the ancient Egyptians appreciated the excellent characteristics of beer. Because no microorganisms grow in beer, it can be stored for a very long time. For the same reason, other cultures produced wine. Fermentation is the key word in this context. In addition to carbon dioxide and some herbs, alcohol is responsible for the long-term quality of beer during storage. The conductivity of beer is between 1.2 and 2.3 mS/cm. Beer brewers have adapted over the last millennia to the various raw materials available in the different areas. This ensures a high versatility of beer.
Ingredients required for brewing
The following ingredients are normally required to brew beer:
Sugar source
Selection influences alcohol content and taste of the end product
A sugar source which ideally contains enzymes in order to break down the starch molecules into small pieces (monosaccharides). This may be any type of grain, but also theoretically any other fruit. The grain can be used in malted form or as a raw fruit. Barley malt is normally used, but wheat or other types of grain can also be utilized for regional products. Rice and maize are used primarily as raw fruits, i.e. as un-malted sources of starch. Industrial sugar sources are also used at times.
The sugar content in a wort is measured according to the Plato scale and is called the original wort. The decisive factor here is the density, i.e. the ratio of the weight. When the wort is produced, the possible alcohol content and the taste of the end product are predetermined by defining the amount of sugar available.
Hops
The most expensive raw material in brewing gives beer its bitter taste
Spices have been used throughout the centuries since the ancient Egyptians. However, this is not true of hops. Evidence proves that hops have only been used to brew beer for around 1,000 years. Prior to this, every possible herb was used. Hops give beer its bitter taste and also produce an aseptic effect. The bitterness of beer differs depending on the individual type. The alpha acid content is the constituent of hops which gives beer its bitter taste. A distinction is made between bitter hops and aroma hops. Hops are primarily grown in Germany (Hallertau, Tettnang), the Czech Republic (Saaz) and the USA. Hops are a tendril plant and need special soils. Their cultivation is very expensive. Only the fruits of the female hop plants can be used.
Hops are the most expensive raw material used in beer brewing. However, only a few hundred grams per 100 liters must be used.
An other property of hops is that it forms a complex with protein. Due to the complex forming a part of the protein (because the proteincontent is too high) can easily be removed by filtration.
Hops are used in three basic forms:
- Natural hops according to how they were picked
- Hop pellets, i.e. cleaned and partially freed bitterns from leaves with different concentrations Hop extracts have become established as the
- final development, especially in fully automatic brewing houses. Hop extracts are highly viscous and must be dissolved in hot water prior to use. They can then be apportioned fully automatically. Hops are added to the copper processor, often in several batches (doses) during different phases in the cooking process.
Hops must also be cooked in order to release their bitterns through isomerization. However, some of the bitterns are also destroyed again through long cooking. It is possible to use isomerized hop extracts. They can be added shortly before the end of the cooking process.
Today different aromas are used to brew beers with a regional character.
Yeast
Different range of produced esters affects the taste
After a bitter sugar water has been prepared in the brewing house, yeast is used. Yeast is a single-cell micro-organism which can absorb simple sugars and turn them into carbon dioxide and alcohol. The yeast passes through two stages.
It multiplies through division as long as oxygen is available. The metabolic process, i.e. alcoholic fermentation, starts once the oxygen is used up. Fermentation continues until no sugar is left. The yeast produces alcohol, carbon dioxide and heat during this process. Since the yeast can only metabolize simple sugars, special importance is attached to mashing.
Beer yeast is a special cultivation which is re-cultivated in many breweries as their own culture. It determines the taste of the beer due to the different range of esters that are produced. A sufficient number of new fresh yeast cells are produced in so-called pure culture units. Basic hygienic rules must be observed very closely during the operation of these units to prevent the yeast suspension from being infected by foreign organisms.
Two types of yeast
A distinction is made between two basic types of yeast:
- Top-fermenting yeast which floats at the end of traditional open fermentation on top of the green beer
- Bottom-fermenting yeast which sinks to the bottom at the end of a fermentation cycle.
The last type can be easily harvested automatically in a cylindroconic tank (CCT). The number of cells in the yeast quadruples during the brewing cycle. Some of these cells die off and are removed from the process. The other cells are reused for the next batch after harvesting. Bottom-fermenting yeast can be used for up to 15 cycles. In principle, there is no limit for top-fermenting yeast. 2,500 runs with a yeast batch are not uncommon.
Water
Hardness is decisive for the type of beer
Water plays an important role for the grain enzymes and yeast. The hardness of the water determined the type of beer in the past. Prior to the use of water softening plants, it was not possible to brew all types of beer everywhere. Every required level of hardness can now be set. Therefore it is possible to brew a beer brand with almost the same taste consistency at many locations throughout the world.
Complex processing
The wort from the brewing house (production time = approx. 12 hours) is fermented in the fermentation cellar (5 to 7 days) at a temperature ranging between 12°C and 20°C and is then placed in cold storage to mature (8 to 24 days at a temperature of up to -2°C after yeast harvesting . The yeast can also carry on metabolizing higher alcohols formed during the turbulent fermentation phase. This process is very important for the taste formation and stability of the beers. Secondary fermentation is influenced by the temperature and the amount of time available.
The finished beer is then freed from all yeast cells and protein precipitations by means of filtration and is then ready for bottling in the pressure tank cellar. The proteins stem from the grain and are responsible, for example, for the froth. Since the proteins cause turbidities when their proportion is too high, some of them are removed.
Most of the internationally brewed beers are still filtered via diatomite pre-coat filters – membrane filtration techniques are still in the development phase. Biological safety can be guaranteed by means of sterile or trap filters. The finished filtered beer now remains in the pressure tank cellar for bottling.
Before the beer is bottled or filled in closed barrels, it is subjected to heat treatment in order to kill off any existing micro-organisms. Short-time heating systems or tunnel pasteurizers are used for this purpose.
Bottled or kegged?
Most of the beer produced worldwide is filled in disposable or reusable bottles. Glass is still used primarily for beer bottles although PET bottles are slowly gaining acceptance. Cans are also in widespread use.
Keg beer accounts for between 15% and 20%, but fluctuates strongly depending on the individual country.
Top beer markets
Beer is measured in hectoliters in the countries which use the metric system. 1 hectoliter is equivalent to 100 liters. Otherwise, tonnes or barrels are widespread. The top 50 beer brewing countries in the world produce a total of around 1.5 billion hectoliters, i.e. 95% of the world beer market. The beer markets in the top 20 countries are as follows (position in 2004):
| Land | Population (Million) | Beer production (Million hl) |
|---|---|---|
| China | 1294.0 | 254.0 |
| USA | 291.0 | 232.2 |
| Germany | 82.4 | 106.3 |
| Brazil | 176.3 | 82.2 |
| Russia | 144.1 | 73.2 |
| Mexico | 102.0 | 66.4 |
| Japan | 127.5 | 65.0 |
| UK | 59.1 | 58.0 |
| Spain | 41.0 | 30.7 |
| Poland | 38.6 | 27.3 |
| South Africa | 44.0 | 25.2 |
| Netherlands | 16.0 | 25.1 |
| Canada | 31.0 | 23.4 |
| South Korea | 47.8 | 19.8 |
| Czech Republic | 10.2 | 18.6 |
| France | 59.4 | 18.1 |
| Australia | 19.3 | 17.3 |
| Ukraine | 48.9 | 16.6 |
| Belgium | 10.3 | 15.7 |
| Thailand | 62.2 | 15.2 |
An analysis of the individual countries reveals different per capita consumption levels for beer.
In western industrial nations per capita beer consumption is much higher than in countries where industrialization is not yet so advanced. This is due on the one hand to the available income, but also to difficult logistics.
The Czech Republic, Belgium, Germany and Ireland, i.e. traditional European countries, top the league table for per capita beer consumption. However, high rates of increase are currently being achieved in Asia.
The world beer type does not exist. However, light end-fermented beers brewed using bottom-fermenting yeast have become established on the international market. In addition to the large internationally operating brewing groups, regional specialties are also continually gaining more acceptance. This underscores the saying "beer needs a home".
Soft Drinks Industry Winters
The rich history of Soft Drinks Industry Winters BV is now in its third century. Today, the bottling company is alive more than ever. With a flexible attitude and high quality standards it has become the largest Dutch soft drinks exporter. In addition, the lubricants of Shell Lubricants (taken over by Fuchs Lubricants) make the machines run optimally and food safe.
"You ask, Winters fills": that's the motto of Soft Drinks Industry Winters BV in Maarheeze (North Brabant, The Netherlands). The company is not directly known to the consumers: the company has never sold soft drinks under its own name. Still, it can look back on a long and rich history. When William Van Hooff laid the founding stone of his brewery on August 5, 1797, he could not have realised that it would become an international soft drink company in two centuries time. By inheritance to the next generations in the year 1873 Jan Winters came in charge. Since then, the brewery was known by his name. In 1918 the production of soft drinks started. Until 1958 Winters only had regional ambitions. Then the company expanded business and Winters became producer of world renowned branded as Seven-Up, Sunkist and Canada Dry. When the domestic sales of soft drinks stagnated, the sight was set on various foreign markets in the seventies. In 1978 the company became part of TLC Beatrice International Holdings. Together with the Belgian soda bottling Sunco, who belonged to the same group, it took over the French mineral water producer St. Alban in 1996. After a management buyout the holding company Sun Beverages Company emerged in 1998, comprising Winters, Sunco and St. Alban.
Contract filling
In 1989 the licenses for the production of Seven-Up and other branded products for the Dutch market ended. Since then all attention is directed to 'contract filling'. This is done on behalf of major international food companies, retailers and other commercial organizations. Winters fills cans for a range of soft drinks, energy drinks, mixed drinks, juices, waters and beers with well-known brands. Between 5 and 10% of production is destined for its own brands, such as Sun Cola and Orange, Party Cola and Orange, Provita multivitamin drink, Maresca mineral water and Megaforce energy drink. Nearly 95% of the volumes is exported worldwide and thus Winters is immediately the biggest Dutch soda exporter. Every year more than 500 million cans are filled, packed and logistically processed. Winters currently employs 120 people in permanent employment and dozens of seasonal workers. Production runs per working day in three shifts for 24 hours and during the peak season in a four or five shifts.
To realize such large numbers, Winters has three production lines. An important part of each line is the can sealing machine running at very high speeds. Two machines seal 1,200 filled cans per minute and the third will do another 625 units per minute. Frans Cox, head of utilities and engineering projects: "Such devices are very capital intensive. It is very important that they remain in good condition to produce an excellent product with a constant quality. "
For the reliability of the sealing machines the right food grade lubricants are essential. Some parts are lubricated with oil, others with grease. Oils are able to dissipate more heat and are regenerable by filtration. They are applied for the lubrication of (plain) bearings and gears. Fats are oils encapsulated in soap skeleton. They have less heat-dissipating properties, and can not be reused. The fats serve, inter alia, for the lubrication of bearings in hemming rollers. Incidentally, their lubricating frequency is lower than that of oils.
One supplier
Until ten years ago, Winters used lubricants from various manufacturers. F. Cox: "However, the need hasd arisen to rationalise the diversity of products and providers. To get a better overview, we decided to give one person decision-making authority and to work with just one supplier. The result is that if there are questions, there is only one firm where you can go to the right person. That's an advantage, because of the high speeds the machines are very sensitive and, if necessary, you should be able to rely on a rapid intervention of your lubricant supplier."
Arjan Nieuwstraten, food sector specialist of Shell Lubricants, adds: "The material of a modern beverage can is much thinner than before and therefore the method of sealing is more critical. So you can imagine the tolerances to have to work with will be smaller than before. The importance of the lubrication is thus become much greater. "
At that time Winters already bought around 70% of its lubricants from Shell Lubricants and, partly by this collaboration this supplier was chosen. "The people at Shell were always coming into action directly when needed. They were also always ready for the start up of new equipment, switching to newer oils or fats, assistance in making lubrication schedules, etc. That's why we did not have to think long about who we wanted to go into business with", F. Cox continues.
In practice, there is now a 'gentlemen's agreement' between the two parties. "A synergy has grown between our companies, based on years of trust", A. Nieuwstraten confirms. "The collaboration with Shell Lubricants is closely aligned with the expectations that we have with respect to our suppliers", F. Cox adds.
Incidentally Shell offers Winters an additional service with the Lubriplan software. This lubrication management system provides an accurate overview of the inspection points for fats and oils in the machines and generates user-friendly instructions. So it is indicated where and with what frequency there has to be checked or lubricated and with what product that needs to be done. "Moreover Lubriplan builds up a history of the objects to be lubricated. It may sometimes appear that periodic lubrication at a certain location is needed less frequent than planned. Such cost optimisations we do proactively for Winters", A. Nieuwstraten continues.
Food safety
In this industry, food safety is of paramount importance and it is essential that no contamination of the filled product occurs. The past decades mineral (engine) oils were used to lubricate can seaming machines. Because these are unfit and improper to come into contact with food, Shell Lubricants has developed a range of food grade oils and fats which are suitable for the lubrication of such equipment. They may be used in the food industry and meet the European standard and the US FDA NSF H1-H1. The FDA (Food and Drug Administration) considers incidental contact of these lubricants with the food product to be acceptable to a level of 10 ppm (parts per million). The lubricants are food safe without compromising on their lubricating properties.
Incidentally, there are two types of food grade products. In some sealing machines the lubrication takes place in a closed circuit: this process is called "recirculating oil '. For such systems Shell Lubricants has developed the synthetic oil 'Shell Cassida Fluid GLE' series. That series has excellent lubricating properties and is recognized by leading suppliers of sealing such as Angelus (USA), FMC FoodTech (Belgium) and Ferrum (Switzerland). A second process is that wherein the lubricant is used only once: the "total-loss system. For this, Shell introduced the food grade mineral oil 'Shell FM Gear Oil TLS 150'. That delivers outstanding performance, even in the presence of water, juice or beer. Moreover, this oil absorbs water, preventing rust.
Remarkable is that these Shell products were developed in cooperation with Soft Drinks Industry Winters. A. Nieuwstraten: "We gave attention both to food security and to the optimization of lubricant performance. At Winter we have gained a lot of knowledge about the lubrication of sealing machines with these products and numerous tests have led to the most sophisticated lubricants for this sector."
Quality Systems
Large beverage producers that have known branded products manufactured through contract fillers not only value high the quality of the final product. Also, the extent to which the production process is controlled and hygiene risks are avoided, plays a major role for them. Winters has responded and holds international quality certificates according to ISO 9000, 14001 and HACCP (hazard analysis critical control points). In addition, the bottling company is certified to the BRC standard (British Retail Consortium). That standard contains guidelines which food producers have to meet in order to supply the large English supermarkets. Finally, for German and French retail chains Winters has the IFS certificate (International Food Standard).
With the high quality food grade lubricants of Shell Lubricants and the high quality standards of Winter the consumer profits.
Featured expert: Pieter Van de Schepop
